Abstract: A mold assembly for manufacturing a trim component of an automotive vehicle. The mold assembly comprises a first mold half having a contoured first mold surface and an outer peripheral edge and a second mold half having a contoured second mold surface and an outer peripheral edge. The mold halves pivotal about a hinge between an open position providing access to the respective mold surface and a closed position with the outer peripheral edge of the first mold half aligned with an abutting the outer peripheral edge of the second mold surface. A cutting ridge is formed around the outer peripheral edge of the first mold half for engaging a bulbous projection formed around the outer peripheral edge of the second mold halves in the closed position whereby upon the injection of a urethane material onto the mold halves, the cutting ridge abuts against the projection and perforates any oversprayed material extending outside of the mold surfaces when the mold halves are moved to the closed position.

Abstract: A method and apparatus for making a formed laminate (20) discloses an applicator (42) for depositing a quick reacting foamable liquid mixture (36) onto a transfer member (38) from which the reacted foam (40) and any foamable liquid mixture that has yet to react is transferred onto a flexible sheet (28). Relative movement of a pair of contoured mold surfaces (74,76) of a mold (68) toward each other compresses the flexible sheet (28) and the foam while the foam is in a transitory state (41) after substantial completion of expansion and before substantial curing has taken place such that it is still viscous. This compression provides a collapsed foam layer (30) and forms the foam as well as the flexible sheet (28) to provide the formed laminate (20). A liner (32) is also provided on the opposite side of the collapsed foam as the flexible sheet.

Abstract: A method and apparatus for making a formed laminate (20) discloses an applicator (42) for depositing a quick reacting foamable liquid mixture (36) onto a transfer member (38) from which the reacted foam (40) and any foamable liquid mixture that has yet to react is transferred onto a flexible sheet (28). Relative movement of a pair of contoured mold surfaces (74,76) of a mold (68) toward each other compresses the flexible sheet (28) and the foam while the foam is in a transitory state (41) after substantial completion of expansion and before substantial curing has taken place such that it is still viscous. This compression provides a collapsed foam layer (30) and forms the foam as well as the flexible sheet (28) to provide the formed laminate (20). A liner (32) is also provided on the opposite side of the collapsed foam as the flexible sheet.

Abstract: A method and apparatus (32) for making a three-dimensionally formed laminate (20) by positioning a mask (62) having an opening (64) above a flexible film (52) for rotation therewith such that a foamable liquid mixture (71) sprayed downwardly through the mask opening onto the film is distribute with the predetermined shape of the laminate to be formed. Separation of the mask (62) and the film (52) with the foamable liquid mixture (71) remaining on the film for processing during a transient state after substantial completion of expansion but before substantial curing. A flexible sheet (26) and the film (52) with the foam (71) therebetween are positioned between first and second three-dimensionally contoured mold surfaces (84,86) that are moved toward each other while the foam is in its transitory state to form the flexible sheet and provide a collapsed foam layer (28) that is bonded to the flexible sheet with the predetermined shape as the three-dimensionally formed laminate (20).

Abstract: A formed laminate (20) is made by a method and apparatus (38) by compressing a flexible sheet (28) and a foamable liquid mixture (50) that has substantially completed expansion but not yet substantially cured so as to form the flexible sheet and provide a collapsed foam layer (30) bonded to the sheet. The flexible sheet (28) is preferably porous cloth, vinyl or leather. A film (56) which is preferably a nonadherent plastic such as polyethylene is preferably positioned in a vertically spaced relationship with the flexible sheet (28) either above or below the flexible sheet with the foamable liquid mixture received therebetween for the expansion prior to the compression that provides the formed laminate. The formed laminate (20) has particular utility as an article of apparel (22) and is preferably made by a quick reacting type foamable liquid mixture (50) which expands in about 8 to 25 seconds and most preferably in about 10 to 15 seconds.

Abstract: A method and apparatus (32) for making a three-dimensionally formed laminate (20) by positioning a mask (62) having an opening (64) above a flexible film (52) for rotation therewith such that a foamable liquid mixture (71) sprayed downwardly through the mask opening onto the film is distribute with the predetermined shape of the laminate to be formed. Separation of the mask (62) and the film (52) with the foamable liquid mixture (71) remaining on the film for processing during a transient state after substantial completion of expansion but before substantial curing. A flexible sheet (26) and the film (52) with the foam (71) therebetween are positioned between first and second three-dimensionally contoured mold surfaces (84,86) that are moved toward each other while the foam is in its transitory state to form the flexible sheet and provide a collapsed foam layer (28) that is bonded to the flexible sheet with the predetermined shape as the three-dimensionally formed laminate (20).

Abstract: A formed laminate (20) is made by a method and apparatus (38) by compressing a flexible sheet (28) and a quick reacting foamable liquid mixture (50) that has substantially completed expansion but not yet substantially cured so as to form the flexible sheet and provide a collapsed foam layer (30) bonded to the sheet. The flexible sheet (28) is preferably porous cloth, vinyl or leather. A film (56) which is preferably a nonadherent plastic such as polyethylene is preferably positioned in a vertically spaced relationship with the flexible sheet (28) either above or below the flexible sheet with the foamable liquid mixture received therebetween for the expansion prior to the compression that provides the formed laminate. The formed laminate (20) has particular utility as an article of apparel (22).

Abstract: A composite cover material to be used for making an integrally foamed article comprises a permeable fabric (10) and a thin layer of latex foam (15) strongly bonded via bonding zone (17) to said fabric. The latex foam layer (15) is made by applying high molecular latex material such as rubbers or synthetic resins as coating to back surface (12) of said fabric, and permitting said latex material to foam and cure. The latex foam has relatively fine mechanical open cells (18) in its internal part and further finer open cells (20) near its outer surface skin (22) which is permeable by virtue of minute holes (21) formed therein. The skin (22), though permeable by minutes holes, can serve as substantially flat and smooth barrier surface against liquid foamable mixtures poured directly onto said skin for making body foam (25) so as to guide slidingly said mixtures therealong and also prevent substantial impregnation into said latex foam.

Abstract: A formed laminate (20) is made by a method and apparatus (38) by relative movement of first and second contoured mold surfaces (44,46) toward each other to compress a flexible sheet (28) and a quick reacting foamable liquid mixture (50) that has substantially completed expansion but not yet substantially cured so as to form the flexible sheet and provide a collapsed foam layer (30) bonded to the sheet. The flexible sheet (28) is preferably porous cloth, vinyl or leather. The quick reacting type foamable liquid mixture (50) which expands in about 8 to 25 seconds and most preferably in about 10 to 15 seconds.

Abstract: A formed laminate (20) is made by a method and apparatus (38) by relative movement of first and second contoured mold surfaces (44,46) toward each other to compress a flexible sheet (28) and vertically spaced film (56) with a foamable liquid mixture (50) there between that has substantially completed expansion but not yet substantially cured so as to form the flexible sheet and provide a collapsed foam layer (30) bonded to the sheet. The flexible sheet (28) is preferably porous cloth, vinyl or leather. A film (56) which is preferably a nonadherent plastic such as polyethylene is preferably positioned in a vertically spaced relationship with the flexible sheet (28) either above or below the flexible sheet with the foamable liquid mixture received therebetween for the expansion prior to the compression that provides the formed laminate.

Abstract: A method for three-dimensionally shaping cover materials such as woven or knitted fabrics, vinyl, leather, and the like is performed by providing a cover material (18) and a layer of foamable liquid reaction mixture such as polyurethane which changes from liquid to a viscous state (16') at the beginning of the gas generating reaction, compressing the combined cover material and the foamed layer in a mold (21,22) having surface configurations corresponding to desired final three-dimensional shapes with the compression being performed when the foam layer has substantially completed rising, but before substantial curing thereof takes place, and then allowing the foamed layer bonded to the cover material to proceed in curing reaction. The three-dimensional cover material shaping is performed by this method without external heat or high pressure so that the cover material can retain its original appearance and high quality.

Abstract: A soft foam article (20) and a method for making the article including a permeable cover (24) of a cloth type sheet construction having an interior (26) and an exterior (28) as well as including an open cell soft polyurethane foam (30) molded in situ within the cover in direct engagement with the cover interior without permeating the cover. The soft foam article (20) includes a soft toy (22) and seating components embodied by a seat cushion (52), a seat back (54), a headrest (56), and an armrest (58). The in situ molding of the soft polyurethane foam is achieved by the use of an aqueous gel coating (34) on the cover interior (26) so as to prevent a liquid foam mixture from permeating the cover while still permitting escape of any air within the cover and of gas generated during the foaming.

Abstract: An apparatus (20) for batch molding open-cell soft polyurethane foam within a mold (22a,22b,104) is provided by introducing into a mixing chamber (26) of a mixing pot (24) a highly activated polyol component and an isocyanate component which are mixed and permitted to foam to provide upward expansion in a viscous state through an upper outlet (28) by free rise that fills the mold (22,104). Such batch molding provides "one age of foam" that enables molding to be performed which was not previously possible. Both a rigid mold (22) and a flexible mold (104) can be utilized. The mixing pot (24) includes a mixer 38 preferably embodied by a rotatable screw (74) that is moved axially to purge the mixing chamber (26) of foam after each cycle.

Abstract: A method and structure for manufacture of a foam cushion article. The method of constructing the cushion article does not require the use of a conventional mold and is performed by placing a frame within the space to be filled with foam. Fabric is then disposed around the frame in a step toward the formation of a preselected geometric shape for the cushion article. Subsequently, a skeletal assembly is positioned externally against the fabric in a final step to achieve the preselected geometric shape. The method allows production of a structure which includes selected areas of fabric bonded and unbonded to foam material. The method also allows substantial degrees of freedom in generating and positioning regions of preformed cushions or of different density foam cushions and in controlling overall strength and bonding between the different cushions and the fabric.

Abstract: A method for molding open cell soft polyurethane foam and a release agent utilized in the method are disclosed as incorporating an aqueous gel coated (30) onto interior surfaces (18,20) of a mold (10) prior to introduction of a foamable liquid polyurethane mixture (32) whose foaming fills the mold cavity (22) as the aqueous gel functions as a solventless release agent that has good lubricity to facilitate filling of the cavity by the foam (34), prevents bonding of the foam (34) to the mold and also provides a thin film-like escape passage (36) for gas generated during the foaming. An acrylic acid polymer that is acid neutralized is preferably utilized to provide the aqueous gel. The acrylic acid polymer and acid neutralizer are most preferably sprayed as separate aqueous mixtures onto the interior mold surfaces to provide the aqueous gel.

Abstract: A soft foam article (20) and a method for making the article are disclosed as including a permeable cover (24) of a cloth type sheet construction having an interior (26) and an exterior (28) as well as including an open cell soft polyurethane foam (30) molded in situ within the cover in direct engagement with the cover interior without permeating the cover. The soft foam article (20) is disclosed as a soft toy (22) and as seating components embodied by a seat cushion (52), a seat back (54), a headrest (56), and an armrest (58). The in situ molding of the soft polyurethane foam is achieved by the use of an aqueous gel coating (34) on the cover interior (26) so as to prevent a liquid foam mixture from permeating the cover while still permitting escape of any air within the cover and of gas generated during the foaming.

Abstract: A method and apparatus (20) for batch molding open-cell soft polyurethane foam within a mold (22a, 22b, 104) is provided by introducing into a mixing chamber (26) of a mixing pot (24) a highly activated polyol component and an isocyanate component which are mixed and permitted to foam to provide upward expansion in a viscous state through an upper outlet (28) by free rise that fills the mold (22, 104). Such batch molding provides "one age of foam" that enables molding to be performed which was not previously possible. Both a rigid mold (22) and a flexible mold (104) can be utilized. The mixing pot (24) includes a mixer 38 preferably embodied by a rotatable screw (74) that is moved axially to purge the mixing chamber (26) of foam after each cycle.

Abstract: A child's safety restraint for use in a motor vehicle includes a retaining member adapted to be held in front of a child on one of the vehicle seats and which is shaped such that in the event of a sudden deceleration of the vehicle, the chest and head of the child will come to rest against a rearmost face of the retaining member. The member has an opening defined within a lower portion thereof through which the child's legs can pass, and has a rigid part on a front face thereof and a resilient squab on the rear face thereof. The rigid part has a progressively reduced thickness as one proceeds in the vertically upward direction, while the resilient part has an increased thickness as one proceeds in the same direction. In this manner, the uppermost portion of the retaining member has an increased squab thickness portion for paticularly protecting the head portion of the child under deceleration conditions.

Abstract: A child's safety chair for vehicles includes a seat member, and a retaining member disposed in front of the seat member, the retaining member having defined within the lower portion thereof a passageway through which the child's legs may pass. The retaining member has a height and width substantially the same as that of the seat member so as to restrain substantially the entire torso of the child under deceleration conditions of the vehicle, and is also separable from the seat member and variably adjustable in its disposition relative thereto whereby different sized children may be accommodated within the safety chair.